Building unit and element



Aug. 15, 1939. e. F. KOTRBATY BUILDING UNIT AND ELEMENT 5 Sheets-Sheet 1Original Filed April 22, L935 \NVENTOR Guy KO/rba/y E M am ATTORNEY g-15, 1939- G. F. KOTRBATY 2,169,255

BUILDING UNIT AND ELEMENT Original Filed April 22, 1935 5 Sheets-$heet 332 b E T a0 r w Ex I I 2 w f i I INVENTOR 3 Guy EAa/rfla/y 5W5] mmATTORNEY Aug. 15, 1939. G. F. KOTRBATY 2,169,255

BUILDING UNIT AND ELEMENT 5 Sheets-Sheet 4 Original Filed April 22, 1935flllllllllll 1011/11/11,

I \NVENTOR ATTORNEY Aug. 15, 1939. G. F. KOTRBATY BUILDING UNIT ANDELEMENT Original Filed April 22., 1935 5 Sheets-Sheet 5 IIIIIIIIIIIIATTORNEY Patented Aug. 15, 1939 UNITED STATES PATENT OFFEQE BUILDINGUNIT AND' ELEMENT Guy F. Kotrbaty, Chestnut Hill, Pa., assignor toFer-O-Con Corporation, New York, N. Y., a corporation of Delaware 11Claims.

This invention relates to improvements in building construction systemsand units and elements therefore. This application is a division of myapplication, Ser. No 17,591, filed April 22, 1935, now matured intoPatent No. 2,101,074, of December "I, 1937.

The improvements of the present invention relate more in detail togenerally prefabricated unitary and composite Wall members and wallunits and to improvements in methods and means for assembling the sameinto completed structures.

The present invention includes as additional features of noveltyimproved wall joint locking and/or decorative members and associatedWall panel features. In addition, the novel improvements of the presentinvention include provisions for the utilization of skeletal orpartly-skeletal structural features in prefabricated elements andstructures including preformed materials and panels thereof, and theerection and assembly of the same into completed units and structureswith or without associating suitable hardenable structural plasticmaterials therewith.

It is a feature of the present invention. to provide a buildingconstruction system formed of self-supporting units mutually abutted andinterlocked by novel structural locking members.

It is another feature of this invention to provide improved structuralelements, including stud members adapted to receive structural lockingand keying members and form composite supporting members therewith.

A further feature of novelty of the present invention is the provisionof improved floor supporting means associated with structural wallsupports.

Another feature of novelty of the present invention resides in thepreparation of multipartite structural wall members and units.

It is also a feature of novelty of the present invention to providepreformed, self-supporting wall sections having substantially completelyfinished surfacings and adapted to be mutually associated in completedwalls by a variety of integral and composite locking and/or keyingmeans.

Other features of novelty include preformed, self-supporting wallmembers provided with a variety of internal heat and moisture insulatingmeans, and including hardened reinforced structural plastic segments asseparate elements adapted to be assembled into a structural entityeither at the place of manufacture or erection or Wholly or in part atboth places.

Special features of novelty also include novel keying and locking meansWith wall structural features with or without integral or separatefurbishing and ornamental and protective elements for wall panel orelement joints.

Particular features of novelty include the preparation and utilizationof preformed, self-supporting wall panel sections of room height orbuilding height mutually associated in complete Wall structures withvertical supporting and locking members incorporated therein or adaptedto be structurally associated therewith.

An exceptional feature of novelty of the present invention is theprovision of a mechanically interlocked skeletal building structureprovided either with preformed structural Wall, floor, ceiling and roofmembers adapted to be assembled into a complete structure or providedwith means for receiving structural plastics to form composite,reinforced structures.

It is also a feature of novelty of the present invention to provideimproved studding and beam elements adapted to be mutually interlockedor keyed together, and so constituted and arranged as to permit the freepassage therethrougn of service pipes and conduits of various kinds.

Other features of novelty of the present invention includeself-supporting building construction units adapted to be associatedwith other like units and separate members to form composite buildingsupporting members provided with panel-receiving means for securingpanelling or surfacings to the Walls thereof.

Another feature of novelty pertaining to this building constructionincludeswalls of self-supporting building units of more than one storyin height and provided with mechanical tie-in means for flooring placedabove basement levels.

It is a feature of the present invention to provide an improved buildingconstruction of steel and structural plastic materials in which wall andfloor joints are mechanically formed.

-It is also a feature of the present invention to provide suchmechanical wall and floor joints Without obstructing continuous Wallmembers of spaced panelling supported on and between composite studding.

Another feature: of novelty of the present invention resides in the useof structural selfsupporting building members of more than one story inheight and adapted to be mutually interlocked with like members to formbuilding walls and to have flooring members mechanically securedthereto.

It is also a feature of novelty and advantage of the present inventionto provide a steel building with the several parts mechanicallyinterlocked and adapted to receive plastic surfacings.

These and other desirable features will be described in the accompanyingspecification and illustrated in the drawings, certain preferred formsbeing shown by way of illustration only, for, since the underlyingfeatures may be incorporated in other specific structural assemblies, itis not intended to be limited to the ones here shown except as suchlimitations are clearly imposed by the appended claims.

In the drawings like numerals refer to similar parts throughout theseveral views, of which Fig. 1 is an elevation of an improved buildingwall structural unit having staggered plasticreceiving panels adapted toform overlap joints with abutted like units;

Fig, 2 is an elevation, partly in broken section, of structural wallunits showing means for securing a variety of surfacings to the panel;

Fig. 3 is a view of a composite stud construction in which the membersare adapted for vertical sliding engagement;

Figs. 4 and 5 are end elevations of mating or coacting sections of thestud assembly shown in Fig. 3;

Fig. 6 is an elevation of a stud including floor connection members andintegral shoe flanges together with panel key receiving means;

Figs. 7 and 8 are elevations of end sections of modified stud members;

Fig. 9 is an elevation of a self-supporting, wall panel section havingstud engaging edge reinforcing members and an overlapping surfacing onone side thereof;

Fig. 10 is a vertical section, partly in elevation of a building Wall,showing foundation connections and floor and roof connections;

Fig. 11 is a starting and aligning channel adapted to receive and lockthe shoe section of the studs of Figs. '1, 8 and 10;

Fig. 12 is a locking key or pin adapted for use with the channel of Fig.11 and the studs of Figs, 6-8;

Fig. 13 is a horizontal section of a wall joint showing multi-partitepanel construction and keying means thereof to form a composite. panel,and showing hair-line surface joints;

Fig. 14 is a view similar to Fig. 13 and showing a modifiedmulti-partite panel together with a combination batten and key;

Fig. 15 is a horizontal section of a wall joint and panel keying meansfor multi-partite reinforced panels of hardened structural plastic;

Fig. 16 is a horizontal section through a wall stud structure showing avariety of panelling members secured thereto;

Figs. 17 and 18 are views similar to Fig. 16 showing a uni-lateralinstallation of modified panelling, and

Figs. 19 and 20 are horizontal sections of spacing members for improvedstud and stanchion constructions.

The building unit shown in Fig. 1, and identified generally by thenumeral 290, comprises a pair of opposed panel sections 291 secured toand spaced apart by end supporting stud and securing members 292. Thesemembers may have any desired shape or form, and will. not bespecifically claimed except in the general combination. The panelsections 291 are so assembled with respect to the supporting studmembers or end sections 292 as to provide one edge 293 thereof flushwith an abutting edge or stud section 292, while the other edge of thepanel member may be provided with an overhanging or overlapping portion294, overlapping the opposed stud section 292. The stud sections may beprovided with key hole locking means or the like 296, on one or bothsides thereof to receive cooperating locking means of abutted structuralmembers. With this type of construction any suitable type of panelling29! may be used, including metal structural members of foraminous metal,including expanded metal lath or the like, and a suitable structuralfinish may be applied thereover to form a preformed unit, or the members290 may be assembled as skeleton structures in a building constructionand cementitious plastics applied over the assembly. It will be notedthat by providing alternating overlapping portions 294, the jointsformed between sections 292 of abutting members will be broken so thatthere will be no through and through joints between inner and outerwalls of the units and wall surface. of which they form a part. Thisconstruction is particularly serviceable where the masking of wall paneljoints is a desired feature. If tiling, brick facings and othersimulated structural finished members are to be applied to one or bothsurfaces of the panellings, the transverse supporting ribs 291 of thepanel surfacings may be substituted for or be formed as track members topermit the utilization of such finishes.

The selfsupporting wall unit shown in Fig. 2, and designated generallyby the numeral 310, is formed in the same manner as member 304, the endstud sections conforming generally to the structure designated by thenumeral 262. The panels 3 may have metal lath or other foraminoussurfacings over the studs and secured thereto and an insulating filling312 may be used to fill the inter-panelling space. In this constructionbrick finishes, indicated generally by the numeral 313, may be securedto and by track members 306 in the same manner as members 301 aresecured to similar members in the wall unit 304. In the presentconstruction of wall units 310, the track members may be spaced closertogether. This wall may have the usual fiashings 249 appropriatelydisposed and suitable wall surfacings 305.

Referring now to Figs. 3, 4 and 5, the composite stud assembly 210includes a pair of abutted and interlocked stud sections designatedgenerally by numerals 211 and 212. The members comprise opposed channelmembers 213 with the channel sections facing each other. The malesection 212 is provided with transverse lattice or cross pieces 214secured to the stud or stanchion sections 213 in any suitable manner, asby welds, bolts, rivets, or the like, all as indicated generally by thenumeral 215. The cooperating lattice stud section of the composite studmember 211 may include the usual end stud or stanchion section 213 withtransverse lattice members 216 having locking and gripping tongues 211associated therewith, either integrally or secured thereto in anydesired manner. The tongues or gripping sections 211 are disposed on theside of stud section 21! nearest that of the opposed section, and areadapted to fit over and engage the lattice sections 214 of member orsection 212 in. vertical sliding and locking engagement. Thisconstruction is particularly adapted for use in the vertical sliding andlocking of abutted building sections into opposed aligned relationship.It will be noted that the sections or tongues 211 are of a widthsufficient to pass between the stud sections 213 of member 212 and besecured and held thereby and prevent weaving or displacement of the studsections.

In Figs. 6 to 12, inclusive, are shown wall panel structures andsupports. In Fig. 6 a hollow stud member is generally rectangular incross section, and has a longitudinal slit at one edge with the opposedside 32 being continuous. The flat sides 33 have apertures 34, usuallyin pairs. Feet 35 are inturned toward each other and engage into slots4| of supporting channel members 43 and held secured therein by lockingkeys 43 in engagement therewith through transverse slots 42. Floormembers 430 may be hung on the connection plates 408 at floor levels andprovided with any suitable surfaces. Wall panels 5| may have surfacings52 and edge binding members 53. The inner panels 5| have edge membersapplied thereover, and fitted with hooks 34a adapted to engage inapertures 34 of the stud sections 30. With pairs of apertures 34, a pairof building panels 5| may be hung on the stud members, back to back, togive a multi-partite insulated wall panel construction. In Fig. 7, themodified stud construction may have a key or supporting bead 39 formedat one side thereof. In Fig. 8 the stud member is shown as a hollowtubing with apertures 34 on all sides thereof.

The hollow studs 30 are shown in combination in Figs. 13, 14, and 15. InFig. 13 the wall panel member 53 each has an inside panel I85 andabutted panel l86, binding members 13!) over the panels, and secured tothe hook members 34a. In Fig. i l, single panels 50 are used, andsliding key 38 is slid over the flanges 38a of the stud section 30. InFig. 15, reinforced concrete panels 6%! may have end supporting andbracing members 63 formed with angular shelving portions 64, stiffeningangles 65, 66, and edge portion 61 with anchor 68. Supporting hooks 34aare secured to section 64 and the panels hung in place on the studmembers 30. The modified panel members 70 are likewise reinforced withcentrally disposed wire mesh or metal lath 12. Special binding and edgeportion 13 are integrally secured in place and these likewise may havehooks 34a by means of which they are hung in place on the stud members30'. In Figs. 16, 17, 18, 19 and 20, panel members of various materialsare shown. In Fig. 16 panel 350 may be made of insulating material andsurfaced with asbestos. Panel 358 may be of cement or concrete andapertured as indicated at 351 to lighten the weight. Panel 365 is athree piece member joined as a unit. Panel 380 is similar to 365, thelatter being reinforced by rod 369, while member 380 has reinforcingribs 383. Various surfacings may be applied to each of these members,and each is adapted to be supported on stud section 34!, which aresecured across supporting bracing members 344 of the latticed studmember 340.

It will be now appreciated that there have been provided improvedstructural building systems including preformed and prefabricated walland floor units and panels either as unitary constructions or ascomposite multi-partite constructions, said panels and building unitsbeing adapted to be secured to improved building supporting members andto engage same in mutual interlocking relationship. In addition, theimprovements of the present invention have been disclosed withstructural skeleton supporting members and units adapted to be used ascarcasses for a variety of preformed building units and sections, asWell as to permit the fabrication and erection of aligned wall andcorner wall constructions and to permit the elaboration of thestructural carcass sections into complete building skeletons over whichstructural cementitious coating and panelling, either cast or applied inpreformed and prefabricated condition in situ, or structural elementsand composite parts may be secured.

While certain novel features of the invention have been shown anddescribed and are pointed out in the annexed claims, it will beunderstood that various omissions, substitutions and changes in theforms and details of the forms and assemblies illustrated and in theirmutual cooperation may be made by those skilled in the art withoutdeparting from the spirit of. the invention.

What is claimed is:

1. A wall construction, including, in combination, hollow verticalsupporting members of generally rectangular cross-section, keyingapertures in the longitudinal edges of the same, and wall panels securedon either side of the said post member, the said wall sectionscomprising composite wall panel members abutted back-to-back, each ofsaid composite wall sections comprising a two-part body portion. oflaminated construction, the edges of the inner lamina being providedwith metallic surfacing and protected by having an outwardly extendingflange portion, the said first lamina and ext riding flange sectionsupporting and securing second lamina with cementitious securing meansdisposed between the two said laminae; locking tongued membersassociated with the exterior surfaces of the said endsupporting andprotecting members and adapted to be engaged by and held in the saidpost members; and exterior finish surfacings disposed over said membersand extending beyond the edges thereof a sufficient distance to permitthe abutment of the said edges with other like members over the exteriorfaces of the supporting posts whereby to provide substantially hair-linejoints between adjacent and aligned wall sections.

2. In a wall construction, preformed wall panelings, including two-part,back-to-back panel sections, each said section being provided withedge-binding members and means for securing the bindings to the members;locking means secured to the edges of the said binding members; andfinish surfacings applied to one side of the panel sections andoverlapping the edges thereof.

3. In a wall panel construction of the type claimed in claim 2, theimprovements comprising a cementitious bonding applied to the unfinishedsurfaces of the panel sections before erection, whereby panel sectionsare adapted to form a unitary composite wall member when abuttedtogether in place.

4. A composite wall construction, including, in combination, a hollowwall-supporting post member, keying apertures in said post, two-partwall sections secured to said post, the said wall sections comprisingcementitious aggregates disposed on and secured to structuralpanel-supporting members; edge-binding members incorporated with saldpanel sections; the said members being generally conformed to thecorners of the post member and provided with locking tongues adapted toengage in looking engagement with apertures in the said post.

5. A structural element, comprising a metal lath backing portion, anedge section comprising a metallic sheet member secured to the lath atthe edges thereof, the said edge member includ ing a stiffening flangeextended outwardly to form an abutting and guide portion and beingprovided with a shoulder portion continued longitudinally of the panelsection and terminating in a rectilinearly disposed flange having aninturned edge section; a cementitious aggregate disposed on the saidmetal lath backing, the said edge sections being formed flush with thelastnamed edge section; and keying tongues secured to the interiorlyextending flange section of the edge members.

6. A wall panel section construction, including a cementitious plasticmass formed in a panel construction; reinforcing, transverse membersdisposed interiorly of the mass; protecting, guiding and structuralmetallic members over the ends of the panels, including an end edgesection having an internal keying flange; an angularly disposed sectioninwardly of the panel member, the said angularly disposed section beingcontinued interiorly of the removable member to form an abuttingshoulder; a reversed column section extending from said shoulder; acementitious plastic aggregate filled in and keyed to the saidshouldered sections; and tongued keying means formed on the lateralexterior surfaces of the said reinforcing metallic shoulder.

7. A wall construction unit comprising latticed stud end sections;surface supporting transverse members disposed between the stud membersand secured thereto; insulating fillings in the members; tile members onthe surfaces of the members, supported in and between the severaltransverse supporting members, the said tilings being provided withgrout materials to water proof same; and flashings secured to the saidunit at floor levels.

8. A wall unit of the type claimed in claim 7, including transversesurfacing members adapted to secure bricks and the like as facings onthe said members, and a filling applied in and between the saidbrick-facing members.

9. A unit wall panel construction, including a vertical channel studmember; keying flanges having keying apertures extending laterally fromthe sides of the channel, panel members abutted against said stud memberand locked thereto, the said panel members having edge-securing and-protecting channels and keys secured to the inner edges of saidchannels; certain of said panel members including internally disposedstrengthening members, and certain others of said panel members havingreinforcing lathing disposed on the interior of the members, and all ofsaid panel members being provided with surfacings overlapping the bodyportion of the said panels and extending to the center of the said studmembers and adapted to form hair-line joints with abutted like membersof adjacent units.

10. In a wall panel construction unit of the class described, acomposite panel unit consisting of a steel reinforced panel with metalchannellike protecting and stiffening members in gripping relation alongits vertical edges, the said channel members being provided withfastening and locking means along one flange of the channel-like member,the said reinforced composite panel being covered. with a surface finishpanel, the edges of said surface finish panel extending beyond the edgesof the reinforced backing panel so as to cover half of the structuralsupporting member of the composite panel unit and provide a hair-linejoint between itself and other abutted companion units and engaged inmutual locking relation with the supporting structure.

11. A prefabricated wall panel section for composite wall units,including a base portion and an overlapping surfacing, edge-stiffeningand -protecting channels on the edges of the base portion, and lockingtongues formed on said edge portions and adapted to fit in and engagelocking apertures in vertical structural members and formed on one sidethereof, the said locking apertures being adapted to receive other likemembers whereby to form composite wall sections having surfacingsextending over exposed portions of stanchion members and adapted. toabut other like units and form hair-line joints; the said panel sectionbeing adapted to be routed or chased on the inner abutting faces toreceive and secure building services.

GUY F. KOTRBATY.

